Cylindrical Battery Lead Routing With Dual Collector Plates
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Solution Overview
Problem
In cylindrical batteries, the positive electrode leads protruding from the radially inward side have a large radius of curvature, leading to high stress and potential breakage, which limits the radial range from which they can be drawn.
Innovation Solution
A cylindrical battery design featuring a bottomed cylindrical exterior housing with an electrode assembly where elongated electrodes are wound with a separator, and multiple second electrode lead parts extending to the bottom, connected through holes in a first current collector plate and bonded to a second current collector plate, reducing stress and increasing flexibility in lead arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If positive electrode leads are bent to the radially outer side toward the ring-shaped member, then electrical connection is achieved, but large stress is applied causing breakage
Solution Approach 1:
A bending prevention member is introduced as an intermediary component between the positive electrode lead and the ring-shaped member. This member has a curved surface that guides the lead during insertion, preventing direct bending of the lead and distributing the mechanical stress, thereby preventing lead breakage while maintaining electrical connection.
Solution Approach 2:
The bending prevention member is pre-installed in the ring-shaped member to provide protective cushioning before the lead insertion process. The curved surface of this member anticipates and prevents the bending stress that would otherwise be applied to the lead, ensuring reliable electrical connection without breakage.
2Reliability
If positive electrode leads are drawn from the radially inward side, then connection is established, but large radius of curvature causes stress concentration
Solution Approach 1:
The bending prevention member serves as a mediator that intercepts and redirects the lead path. Instead of the lead bending directly with a large radius of curvature, it follows the guided path along the curved surface, distributing stress and preventing concentration at critical points.
3Ease of manufacture
If leads are arranged with fixed positions, then manufacturing is simplified, but degree of freedom in arrangement is limited
Solution Approach 1:
The bending prevention member with its curved surface provides a universal guiding structure that accommodates multiple lead arrangements. Rather than requiring fixed, predetermined lead positions, the curved surface allows leads to be inserted from various radial positions while maintaining proper bending prevention, thus increasing arrangement flexibility without complicating manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the degree of freedom in lead arrangement and reduces the likelihood of lead breakage, allowing for more flexible and reliable lead protrusion from the battery.
Implementation Method 1
a tip portion of each of the plurality of second electrode lead parts is held between the first current collector plate and the second current collector plate and is electrically connected to the second current collector plate
Data Source
AI summary
A cylindrical battery having a bottomed tubular exterior can; an electrode body in the exterior can and around which a long positive electrode and a long negative electrode are wound with a separator therebetween; a plurality of negative-electrode lead parts extending from a long negative-electrode current collector of the negative electrode toward the bottom part of the exterior can; a first current-collector plate that is disposed on the bottom part side of the electrode body and that has at least two through-holes at the positions different from each other in the radial direction; and a second current-collector plate disposed between the first current-collector plate and the bottom part. The negative-electrode lead parts each pass through any one of the through-holes. Leading-end portions of the plurality of negative-electrode lead parts are sandwiched between the first current-collector plate and the second current-collector plate, and are electrically connected to the second current-collector plate.